Method of shortening a window shade roller

ABSTRACT

A method of reducing the length of a window shade roller assembly having a tubular roller, a shade convolutely wound thereon and an end plug, including inserting the end plug in a retracting mechanism, cutting the roller and reinserting the plug. The dimensions and configuration of the roller assembly enable it to be utilized in conjunction with a conventional window shade cutting machine and adjusted after assembly.

United States Patent 11 1 1111 3,772,762 Stark [451 Nov. 20, 1973 [54] METHOD OF SHORTENING A WINDOW 3,362,461 1/1968 Stark 160/323 SHADE ROLLER 320,247 6/1885 Hartshorn 160/325 Inventor: Martin H. Stark, 1301 Wheeler,

Saginaw, Mich.

Filed: Jan. 8, 1973 Appl. No.2 321,620

Related US. Application Data Division of Ser. No. 885,065, Dec. 15, 1969, Pat. No. 3,722,573.

US. Cl 29/426, 29/428, 29/525 Int. Cl. B23p 19/00 Field of Search 29/426, 525, 200 R,

References Cited UNITED STATES PATENTS 11/1962 Gast, Jr 160/3 X Primary Examiner-Charles W. Lanham Assistant Examiner Victor A. DiPalma Attorney-Raymond E. Scott [57 ABSTRACT 5 Claims, 7 Drawing Figures METHOD OF SHORTENING A WINDOW SHADE ROLLER RELATED APPLICATION This application is a divisional application of my copending application for United States patent, Ser. No. 885,065, filed Dec. 15, 1969, now U.S. Pat. No. 3,722,573.

BACKGROUND OF THE INVENTION 1. Field Of The Invention This invention relates to window shade roller assemblies and more particularly to shade rollers fabricated of laminated paper and end plugs especially adapted for use with such rollers and standard window shade cutting machines.

The invention is especially directed to window shade roller assemblies wherein the roller element of the assembly is a wound paper tube of multiple plies (either convolutely or spirally wound) and the plies of which are adhesively bonded to one another. Rollers possessing the necessary structural rigidity can be conveniently formed utilizing techniques well known in the paper tube making art.

2. The Prior Art In the usual case, window shade rollers are made of wood. They are manufactured in a number of standard lengths. Because of variations in window dimensions, it is frequently necessary to trim a standard length roller to fit a window frame in which it is to be used. The rollers conventionally sold with a space cap and torsion spring mounted in one end, and at the other end an end cap, through which a round pivot or gudgeon pin is driven into the roller. To trim the roller to length, the end cap and pivot pin are removed and trimming is done at that end of the roller.

Special window shade cutting machines have been developed for this purpose. In a typical operation, the roller is inserted in the machine, a chuck grips the pivot pin, and the chuck is then retracted, removing the pin and end cap from the end of the roller. The roller is then removed from the first position and positioned on another part of the machine where the shade and the end of the roller are trimmed. The roller is then placed back in the first position and the gudgeon pin and end cap replaced, after which the chuck is released from the gudgeon pin.

THE PROBLEM The machines customarily used for cutting window shades are designed for use with wooden rollers having gudgeon pins. Any acceptable substitute roller assembly should be adapted for use with these conventional window shade cutting machines.

SUMMARY OF THE INVENTION A window shade roller is provided which is formed of laminated paper with a hollow interior for receiving an end plug. If desired, a composite, partially wooden roller can be provided within the scope of this invention. However, such composite rollers have the plug end (i.e., that end trimmed to length) formed of paper. Typically, the internal diameter of the roller is about two-thirds of an inch and the external diameter is about 1 inch. Preferably the end cap or plug is a molded one piece plastic article having a circular flange with a diameter somewhat less than three-fourths of an inch and a roller support pin fixed in a bore in the flange against movement relative thereto and projecting from one side thereof to form the sole support beyond the flange. A reduced diameter plug portion is formed on the other side of the flange, and is received for axial adjustment within the interior of the roller. The plug portion is threaded on the outside, and the threads are of a dimension to deform the inner periphery of the shade roller to lock the end cap against rotation relative to the shade roller at a selected position of axial adjustment.

The configuration and size of the end cap or plug are such that the assembly can be used with a conventional window shade cutting machine.

Accordingly, it is an object of the invention to provide a window shade roller assembly employing a paper roller having a pivot pin carrying end cap or plug which is adapted for use with a standard window shade cutting machine.

The method of reducing the length of a window shade roller assembly described herein includes the steps of supporting one end of the roller assembly on a conventional window shade cutting machine having a retracting mechanism receiving the opposite end of the roller assembly including a beveled opening receiving the tubular roller, an axial bore receiving only the 7 end plug and an axially displaceable chuck receiving and retaining the end pin and retracting to remove the plug from the roller assembly. The diameter of the tubular roller is greater than the internal diameter of the bore, but less than the maximum diameter of the beveled opening, to engage the beveled opening during removal of the end plug. The end plug includes a radial flange having a diameter greater than the internal diameter of the tubular roller, but less than the internal diameter of the retracting mechanism bore, such that the end plug is received within the bore and retracted, as described above. The end plug also has a reduced cylindrical portion which is received within the end of the tubular roller member including radial projections which retain the end plug in the roller member. The endplug is then removed from the tubular roller by retracting the chuck within the bore to first abut the roller against the beveled opening, as described above, and then telescopically removing the end plug from the tubular member, releasing the roller. The tubular roller is then cut to the desired length at a separate station, for example, and the end plug is reinserted in the cut end of the tubular roller by aligning the roller with the end plug and extending the chuck to force the plug into the roller.

Other objects and features of the invention will become apparent by reference to the following specification and to the drawings.

IN THE DRAWINGS FIG. 1 is an exploded perspective view of one embodiment of the invention;

FIG. 2 is an elevational view of the embodiment of FIG. 1;

FIG. 3 is an end view of the embodiment of FIG. 2;

FIG. 4 is a plan view, with parts in phantom of the embodiment of FIG. 1 in an assembled position;

FIG. 5 is a perspective view of a standard window shade cutting machine;

FIG. 6 is an enlarged view of the end cap removing portion of the standard shade cutting machine; and

FIG. 7 is a cross-sectional view through line 7-7 of FIG. 6.

The window shade roller assembly 10 of this invention is shown in FIG. 1. The assembly 10 comprises a window shade roller 12 which is an elongated hollow cylindrical tube, preferably formed from a convolutely wound sheet of paper, the convolutions of which are adhesively bonded to each other.

The assembly 10 has an end cap 14 or plug for the roller formed of a molded plastic or metal material. The end cap 14 has a circular flange 16 greater than the internal diameter of the tube 12 and smaller than the outside diameter of the tube. integrally molded with the flange on one side thereof is a section of reduced diameter 18 generally elliptical in shape to provide opposed parallel flat sides 20 adapted for receiving a wrench or other turning device, for axial adjustment of the cap 14. An axially extending tubular plug portion 22 projects from the opposite side of the flange. Spiral screw threads 24 are molded into the surface of the plug portion 22; these threads 24 may either be continuous or interrupted. The threads grip and deform the inside wall of the roller 12 when the cap is inserted in the end of the roller. The thread diameter dimension is such that the thread will fit properly within the roller member 12 and prevent the cap 14 from accidentally turning in the roller. If the thread diameter is oversized, the cap 14 will be too difficult to force in the roller 12, while an undersized thread will allow the cap 14 to turn too freely relative to the roller 12, an undesirable situation.

The use of interrupted threads allows the plug 14 to be inserted more easily into the roller 12, because there is less thread to grip the inside wall of the roller 12, and less axial alignment problems are presented.

The cap 14 has a center bore extending through the section of reduced diameter 18 and flange 16. A gudgeon pin 28 is inserted in the center bore. The pin 28 has an outwardly projecting flange 30 which abuts the end of the section of reduced diameter 18, limiting the extent of penetration of the pin 28 into the cap 14. The bore diameter is critical in that the pin 28 will split the plastic when it is inserted in the bore if the bore is smaller, whereas if the bore is any larger the pin 28 will be pulled out, rather than the entire cap 14, when the pin 28 is grasped in the chuck of the cutting machien and the chuck retracted, as subsequently described herein. The pin 28 is adapted to enter the circular hole of the usual window shade roller mounting bracket (not shown) for rotatably supporting one side of the window shade roller.

The window shade roller assembly of this invention is adapted for use in conjunction with a conventional window shade cutting machine. Such a window shade cutting machine is shown in FIGS. 5, 6 and 7.

This machine 32 comprises a support base 34 having an elongated support and measuring bed 36 for a window shade roller extending therefrom. The support bed 36 has an adjustable clamping device 38 mounted on it for receiving one end (the end containing the spring) of a window shade. A housing 40 having a beveled mouth 42 and an internal bore 44 is mounted on the support base 34 for receiving the opposite end of the window shade. The diameter of the bore 44 is conventionally 0.750 inch. An adjustable chuck 46 is mounted inside a cylinder 48 in the housing and is used to grip the pivot pin 28. The chuck 46 is axially movable within the bore 44 of the housing 40 by means of a handle 50 having threads (not shown) engageable with threads on the bottom of the cylinder 48. Thus, the chuck 46 and cylinder 48 move axially as one piece. A handle 52 connected to the chuck 46 is used to adjust the chuck opening.

In operation, a window shade assembly 10 is mounted between the clamp 38 and the mouth 42 of the housing 40. The chuck is then moved forward in the bore 44 and clamped around the gudgeon pin 28. The chuck 46 is then retracted by means of the handle 50, bringing the end face of the roller 12 into contact with the mouth 42, halting the roller 12 against it. Further retraction of the chuck 46 into the bore 44 draws the end cap 14 out of the roller 12 and into the bore 44. The roller 12 is then removed and cut to the desired length on another part of the apparatus, not specifically described. Thereafter it is reclamped between the clamp 38 and the mouth 42 of the housing 40, the chuck 46 moved forward, and the end cap 14 reinserted into the end of the roller 12. Thereafter the chuck 46 is disengaged from the pin.

The diameter of the flange 16 of the end plug 14 is critical since, if it were too large, it would not retract into the bore 44 in the housing on the window shade cutting machine. Conversely, if the flange 16 were too small, it would slide into the internal cavity of the roller 12. Thus, the cap 14 would not be properly positioned on the roller 12.

A shade cutter such as has been described above is sold by the Star Shade Cutter Co., St. Joseph, Michigan, under the designation Star Model M-200.

Even using a conventional shade cutting machine, it is not always possible to cut the roller 12 to an exact fit. Therefore, the plug 14 can be axially adjusted relative to the roller 12 once it is cut, to either lengthen or shorten the effective width of the window shade. This can be done by gripping the section of reduced diameter 18 with a pair of pliers and either screwing the cap 14 in or out of the roller 12.

Thus, the present invention provides an end cap or plug 14 adaptable to conventional shade cutting and trimming machines presently used, often by inexperienced and unskilled persons, in the cutting and trimming of conventional wooden rollers having removable gudgeon pins. There is exact interchangability so far as removal of the gudgeon pin and plug is concerned of the roller assembly herein described and the currently utilized wooden assembly.

I claim:

1. A method of cutting a window shade roller assembly to fit an exact opening in a window comprising the steps of positioning a window shade roller assembly with shade convolutely wound thereon in a first position in a standard window shade cutting machine, said machine including a support base having an elongated support and measuring bed for a window shade roller assembly, means for fixing one end of a window shade assembly to said base, a housing for receiving the other end of the assembly mounted on the opposite end of said support base and having an internal bore, a beveled mouth at the forward end of said internal bore, a retractable chuck mounted within said bore, and means for retracting said chuck; said window shade roller assembly comprising a paper tubular roller member having an external diameter larger than the diameter of said bore, an end plug having a peripheral flange having a maximum dimension less than the diameter of said bore and a minimum dimension greater than the internal diameter of the tubular roller member, a gudgeon pin fixed in said plug to project from one side thereof externally of said roller member, said plug also having a reduced diameter portion adjustably received within the interior of said tubular roller member, said reduced diameter portion having exterior peripheral projections engaging the inner wall of said roller member to retain said plug against rotation relative to the roller member at any one of several selected positions of axial adjustment; engaging said chuck with said gudgeon pin to telescopically axially pull said plug from said roller member as said chuck is retracted into said bore, any subsequent movement of said roller member being prevented by abutment of the end of said roller member with the mouth of said housing, removing said roller member with shade wrapped around it to another posi tion on said window shade cutting machine and cutting said roller member and shade to the desired dimension, repositioning said roller member and shade on said standard window shade cutting machine in the first original position, and reversibly inserting said plug into the end of said roller member.

2. The method of claim 1 which further includes the step of axially adjusting the position of the end plug after the plug has been reinserted into the end of the roller member.

3. A method of reducing the length of a window shade roller assembly having a tubular roller, a shade convolutely wound thereon and an end plug adapted to support the roller assembly in a window opening, comprising the steps of: supporting one end of said shade roller assembly on a conventional window shade cutting machine; said machine having a clamp means for retaining said one end of the roller assembly and a plug retracting mechanism receiving the opposite end of said roller assembly, said mechanism including a beveled opening terminating in a bore, an axially displaceable chuck mounted within said bore and extensible within said beveled opening and means for extending and retracting said chuck within said bore; said tubular roller having an external diameter greater than the internal diameter of said retracting mechanism bore, but less than the maximum diameter of said beveled opening, said plug having a reduced diameter cylindrical portion received within said opposite end of said tubular roller including radial projections engaging the interior surface of said tubular roller and retaining said plug within said roller at selected positions against relative movement, said end plug also including a radial flange engaging the end of said roller having a maximum dimension less than the internal diameter of said bore, but greater than the internal diameter of said tubular roller and a pin secured to said end plug and projecting axially therefrom; disposing and securing said end plug within said chuck; telescopically retracting said chuck within said mechanism bore to first abut said roller other end against said beveled opening and then telescopically removing said end plug from said tubular roller, releasing said roller; removing and cutting said roller and shade to a predetermined length; axially aligning said tubular roller and said end plug on said machine; inserting said end plug in said tubular roller by extending said chuck; and, releasing said end plug pin.

4. The method defined in claim 3, wherein said radial projections of said plug extend spirally on said reduced cylindrical portion, including the final step of telescopically adjusting said plug in said tubular roller to adjust the overall length of said roller assembly.

5. The method defined in claim 3, wherein said end plug includes a reduced distal end portion, receiving said pin, having opposed tool receiving flats, including the step of telescopically adjusting the position of said end plug, within said tubular roller, by engaging said distal portion flats with a gripping tool and inserting or retracting said end plug. 

1. A method of cutting a window shade roller assembly to fit an exact opening in a window comprising the steps of positioning a window shade roller assembly with shade convolutely wound thereon in a first position in a standard window shade cutting machine, said machine including a support base having an elongated support and measuring bed for a window shade roller assembly, means for fixing one end of a window shade assembly to said base, a housing for receiving the other end of the assembly mounted on the opposite end of said support base and having an internal bore, a beveled mouth at the forward end of said internal bore, a retractable chuck mounted within said bore, and means for retracting said chuck; said window shade roller assembly comprising a paper tubular roller member having an external diameter larger than the diameter of said bore, an end plug having a peripheral flange having a maximum dimension less than the diameter of said bore and a minimum dimension greater than the internal diameter of the tubular roller member, a gudgeon pin fixed in said plug to project from one side thereof externally of said roller member, said plug also having a reduced diameter portion adjustably received within the interior of said tubular roller member, said reduced diameter portion having exterior peripheral projections engaging the inner wall of said roller member to retain said plug against rotation relative to the roller member at any one of several selected positions of axial adjustment; engaging said chuck with said gudgeon pin to telescopically axially pull said plug from said roller member as said chuck is retracted into said bore, any subsequent movement of said roller member being prevented by abutment of the end of said roller member with the mouth of said housing, removing said roller member with shade wrapped around it to another position on said window shade cutting machine and cutting said roller member and shade to the desired dimension, repositioning said roller member and shade on said standard window shade cutting machine in the first original position, and reversibly inserting said plug into the end of said roller member.
 2. The method of claim 1 which further includes the step of axially adjusting the position of the end plug after the plug has been reinserted into the end of the roller member.
 3. A method of reducing the length of a window shade roller assembly having a tubular roller, a shade convolutely wound thereon and an end plug adapted to support the roller assembly in a window opening, comprising the steps of: supporting one end of said shade roller assembly on a conventional window shade cutting machine; said machine having a clamp means for retaining said one end of the roller assembly and a plug retracting mechanism receiving the opposite end of said roller assembly, said mechanism including a beveled opening terminating in a bore, an axially displaceable chuck mounted within said bore and extensible within said beveled opening and means for extending and retracting said chuck within said bore; said tubular roller having an external diameter greater than the internal diameter of said retracting mechanism bore, but less than the maximum diameter of said beveled opening, said plug having a reduced diameter cylindrical portion received within said opposite end of said tubular roller including radial projections engaging the interior surface of said tubular roller and retaining said plug within said roller at selected positions against relative movement, said end plug also including a radial flange engaging the end of said roller having a maximum dimension less than the internal diameter of said bore, but greater than the internal diameter of said tubular roller and a pin secured to said end plug and projecting axially therefrom; disposing and securing said end plug within said chuck; telescopically retracting said chuck within said mechanism bore to first abut said roller other end against said beveled opening and then telescopically removing said end plug from said tubular roller, releasing said roller; removing and cutting said roller and shade to a predetermined length; axially aligning said tubular roller and said end plug on said machine; inserting said end plug in said tubular roller by extending said chuck; and, releasing said end plug pin.
 4. The method defined in claim 3, wherein said radial projections of said plug extend spirally on said reduced cylindrical portion, including the final step of telescopically adjusting said plug in said tubular roller to adjust the overall length of said roller assembly.
 5. The method defined in claim 3, wherein said end plug includes a reduced distal end portion, receiving said pin, having opposed tool receiving flats, including the step of telescopically adjusting the position of said end plug, within said tubular roller, by engaging said distal portion flats with a gripping tool and inserting or retracting said end plug. 